System for high density testing of batteries within an environmental test chamber

ABSTRACT

The All Test Platform (ATP) provides provides a safe and easy way to test batteries within an environmental test chamber. The ATP enables rapid changing of batteries and battery types between tests, and provides the highest density per square foot of environmental test chamber space available for battery testing. The ATP combines multiple components critical for battery testing into a configurable, scalable, safe, and high density battery testing platform.

CROSS-REFERENCE TO RELATED APPLICATIONS

This utility patent application claims priority from U.S. provisionalpatent application Ser. No. 62/686,703, filed Jun. 19, 2018, titled“System for High Density Testing of Batteries within an EnvironmentalTest Chamber”, naming inventors Beran Peter and Brockton Kenyon.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent file or records, but otherwise reserves all copyrightrights whatsoever. Copyright 2019, Associated Environmental Systems.

BACKGROUND Field of Technology

This disclosure relates to testing batteries, and more particularly to afixture within an environmental chamber capable of supporting multiplebatteries under test.

Background

Batteries, specifically those utilized in consumer electronics such ashand held electronics, smartphones and computers, need to be tested.More powerful batteries, such as those powering electric vehicles andappliances, face similar testing needs. Battery behavior such asdurability, charge life, and physical expansion across a wide range oftemperatures is critical for successful consumer electronic deployment.All batteries produced for a specific battery line, which may spanmultiple manufacturing lines, factories, and countries, must meet aminimum baseline performance. As performance of batteries is dependenton many variables during production, such as temperature when created,testing to ensure baseline performance is critical. There are also anumber of very public issues (such as certain smartphone batteriescatching fire or exploding) that drive a need for testing of batteriesacross a wide range of environmental conditions.

The quantity of batteries that need to be tested is very large. Forexample, approximately 380 million smartphones were sold in the firstquarter of 2018, which leads to smart phone battery usage of over abillion a year. With a sample rate of 8% (which is common) of thosebatteries that go through extended testing over temperature ranges andextremes, that represents eighty million batteries that need to betested per year. This provides a challenge as to how to best leverage acomprehensive testing environment over the largest quantity of batteriespossible.

Additionally, companies who provide electronics that use batteriestypically have multiple use cases, battery types, and sizes that alsoneed to undergo environmental testing. Companies such as Samsung, Apple,Microsoft, and Google provide battery powered electronics in multipleformats, i.e. Smartphones, Tablets, Laptops etc. Tesla produces electricvehicle batteries at the Gigafactory. Each of these has a differentsize, format, and type of battery with the same testing requirements.

There are many existing environmental test chambers, as well as batterycharging/discharging systems which can connect to the chamber to powerand monitor battery tests. Cabling and connection is specific anddedicated to battery type, creating an intensive and time consumingprocess for swapping batteries being tested, and becomes even worse whenswapping battery types.

Solutions available in the market are typically singular use and purposebuilt. A single shelf is placed in an environmental test chamber,battery connections are made (depending on the type of battery). Eachbattery connection is hard wired to a cable that is routed out a hole inthe chamber to an external testing device that provides charging anddischarging of the battery. Each of those cables might be tie wrappedtogether to try to make it a little neater. A lab technician will try toget as many batteries (perhaps 8 to 12) on the single shelf as possible.

After those batteries are tested, the technician then reaches into thechamber, removes the tested batteries, and replace them with a new setof batteries, likely having to disconnect and reconnect the interface tothe external testing platform. Alternatively, the batteries aredisconnected and the shelf is removed from the test chamber, newbatteries are placed on the shelf and the shelf and batteries arere-installed in the chamber for the next test.

If a different type of battery is required for testing, the shelfitself, and the battery connection, would need to be replaced.

Time to set up a test per battery, time to test per battery, andreconfigurability of the test environment are all critical issues thataffect battery testing throughput and have a significant effect oncapital equipment costs and requirements needed to achieve batterytesting quantities.

U.S. Patents

U.S. Pat. No. 9,207,283 (“UNIVERSAL BATTERY CHARGER AND METHOD OF USETHEREOF”, inventor Partee, issued Dec. 8, 2018) discloses, in theAbstract, “A system and method for charging batteries. Stops areadjusted for each of the batteries to secure the number of batteries inplace. The batteries are placed to abut the stops. Adjustable contactsof the battery charger are positioned against terminals of thebatteries. The batteries are secured within the receptacles of thebattery charger. The batteries are charged.” Partee's charger may alsobe configured to test a number of batteries.

U.S. Pat. No. 8,816,692 (“TEST SYSTEM FOR A BATTERY MODULE”, inventorTom, issued Aug. 26, 2014) discloses, in the Abstract, “A test systemfor a battery module is provided. The system includes a housing having abottom plate; and first, second, third and fourth side walls coupled tothe bottom plate that defines an interior region. The system furtherincludes a mounting fixture that fixedly holds the battery modulethereon. The system further includes first, second, third and fourthcoupling members. The system further includes a lid coupled to thehousing utilizing the first, second, third and fourth coupling members.The system further includes a battery charging system that charges thebattery module.”

U.S. Patent Application Publications

United States Patent Application Publication No. 2011/0273181 (“BATTERYTESTING METHOD”, inventors Park et al., published Nov. 10, 2011)discloses, in the Abstract, “The present invention allows batteries tobe tested in conjunction with being re-charged, and identifies failed orfailing batteries before they are put to further use. The presentinvention can simultaneously test and charge multiple batteries, and cansimultaneously test and charge different types of batteries. A methodaccording to various aspects of the present invention comprises:identifying, by a computer system comprising a user interface, aprovided battery to be tested; receiving, through the user interface, aselection one or more tests to perform on the battery; and performing,using a battery testing system, the one or more tests on the battery. Inthis method, the battery testing system is in communication with thecomputer system, and the battery testing system comprises a batteryinterface for coupling with the battery.”

What is needed is a platform that enables increased battery testingthroughput and efficiency by delivering a high density (quantity)testing of batteries per sq ft. of testing volume, monitoring batterybehavior during testing, enabling environmental condition testing, andalso allowing for configurability for multiple types of batteries to betested.

BRIEF SUMMARY

The All Test Platform (ATP) provides provides a safe and easy way totest batteries within an environmental test chamber. The ATP enablesrapid changing of batteries and battery types between tests, andprovides the highest density per square foot of environmental testchamber space available for battery testing. The ATP combines multiplecomponents critical for battery testing into a configurable, scalable,safe, and high density battery testing platform.

The ATP allows for specific battery types to be easily inserted onsliding shelving that is interchangeable depending on the battery typeand testing needs. These shelves allow an operator/test technician toslide the shelves out, change the batteries, slide back in, and begintesting without any requirement to disconnect and reconnect externaldevices and test equipment. Time savings and testing density areoptimized in the platform.

To utilize the platform for a different battery type, a batteryinterface board is changed, the desired shelving is installed, and theplatform is now available for high density testing of a different,unique battery type.

Features and Advantages

The ATP provides:

The ability to place a high quantity of batteries in the chamber,maximizing test density.

Interface via swappable circuit boards for connectivity to varyingexternal testing devices.

Configurability via swappable and interchangeable circuit boards to testdifferent types of batteries.

Slidable shelving systems that provides ease and safety of batteryinsertion into the test environment with no external disconnectrequired.

A modular system which is easy to use and configure based upon the userrequirements.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, closely related figures and items have the same numberbut different alphabetic suffixes. Processes, states, statuses, anddatabases are named for their respective functions.

FIG. 1 shows two stacked environmental test chambers with All TestPlatforms (ATPs) within, connected to an external battery powering andmonitoring system. One environmental test chamber is closed, and theother is open with one carrier slid out and enlarged for a detailedview.

FIG. 2 shows an environmental test chamber with an ATP within.

FIG. 3 shows an ATP within an environmental test chamber.

FIG. 4 shows a frame of an ATP.

FIG. 5 shows a carrier of an ATP.

FIG. 6 shows a carrier with one shelf inserted and a second shelf beinginserted.

FIG. 7 shows a flexible cable carrier used within an ATP.

FIG. 8 shows a carrier without shelves slid out of an ATP, with flexiblecable carrier visible beneath.

FIG. 9 shows a wiring path within an ATP for connecting with an externalbattery powering and monitoring system.

FIG. 10 shows different ABIBs.

FIG. 11A shows a carrier with an ABIB about to be connected, and FIG.11B shows the carrier with the ABIB connected.

FIG. 12 shows an ATP-C ABIB with paired clips for connecting to batteryleads.

FIG. 13 shows an ATP-P ABIB connected to pack batteries on thenon-conductive shelving, and cabling harnessed through the flexiblecable carrier connected to the ABIB.

FIG. 14 shows a flex cable assembly used to connect batteries to anATP-P ABIB.

DETAILED DESCRIPTION, INCLUDING THE PREFERRED EMBODIMENT

In the following detailed description, reference is made to theaccompanying drawings which form a part hereof, and in which are shown,by way of illustration, specific embodiments in which the invention maybe practiced. It is to be understood that other embodiments may be used,and structural changes may be made without departing from the scope ofthe present disclosure.

Operation

Referring to FIG. 1, the All Test Platform (ATP) 100 integrates a numberof different components in a scalable and configurable manner to addressthe issues of the existing solutions in the marketplace. The ATPplatform 100 holds and connects batteries, fits within an environmentaltest chamber 110, and routes wiring to an external system 120 poweringand monitoring battery tests. MACCOR is on example manufacturer of suchexternal systems, and also manufactures a temperature chamber.Associated Environmental Systems manufactures various environmental testchambers for temperature, humidity, corrosion, and other testing. TheATP is used within these chambers, or other test chambers from othermanufacturers. Multiple test chambers 110 may be stacked or otherwiselinked for larger scale testing.

Referring also to FIG. 2, environmental test chamber 110 typicallycontains a control section 200 for generating and controlling theconditions of the test, and a testing section 210 into which items to betested are placed. The ATP platform fits into testing section 210. Thefigures illustrate testing section 120 as open on at least one side,which is done to illustrate the ATP components as in place within thetext chamber. In operation, sides and covers may be attached to enclosetesting section 210 and preserve the desired environmental testingconditions.

One example of battery testing in an environmental test chambertypically entails the chamber and batteries to be set at specifictemperatures. For example, very cold to simulate cold weather deviceconditions. The longevity, performance and capacity of the battery arethen tested by charging and discharging the battery in a test cycle.

Referring also to FIG. 3, the parts of the ATP 100 include:

-   Frame 300-   Rails 310-   Carrier 130-   Non-Conductive Shelf 140-   Flexible cable carrier, with support and mounting 320-   Battery Interface Board (ABIB) 150-   Holders, clips, or connectors for Battery connection 160

Frame

Referring also to FIG. 4, frame 300 is constructed to fit inside anenvironmental test chamber, allowing for the addition of up to 4carriers (sliding shelves) and related cabling harnesses. The frameincludes bottom and side walls, a connection support on one end holdingvertical position of the side walls, and an exposed end allowing slidingof the shelves. A side wall gap 400 may be included to improveintegration and allow proper flow of environmental factors generatedwithin the test chamber. Depending on the size of the chamber that itwill be placed in to add high density battery testing capabilities, thedimensions of the frame then dictates the size of the carrier, how manyshelves per carrier and how many carriers per frame. Smaller chambersmight only have 3 carriers with a single shelf on each, allowing formaximum battery quantity of 24 batteries. This option may be chosenbased on space constraints. For a less constrained physical environment,a frame that fits in a 8 CU FT internal chamber working volumes wouldsupport 4 carriers, 8 shelves and up to 64 batteries available for test.All frame material is made utilizing stainless steel, as the chambertesting environment can contain humidity and stainless steelconstruction eliminates the possibility of rust.

The Frame provides the structure for the shelving to be integrated, aswell as the flexible cable carrier track for the electronic harnessrouting.

Rails

Rails 310 attached to the frame connect with rail attached under eachcarrier, creating slide-out access to shelves, ABIBs, and batteries.

Carrier

Referring also to FIG. 5, carrier 130 acts as a sliding shelf, able toslide in and out of the ATP on rails 310 connected to the frame. Thecarrier provides a mounting platform for two non-conductive shelves, andan ABIB between the non-conductive shelves. In the preferredconfiguration, the carrier is 19.118″×23″ and made of stainless steel.

Non-Conductive Shelf

Referring also to FIG. 6, each carrier 130 provides mounting for twonon-conductive shelves 140. Each shelf integrates into the carrier,providing a surface for a device under test (DUT) to be placed on. Thissurface is designed to promote airflow, be non-conductive, and have aflatness specification. Depending on the configuration, the shelf cansupport different quantities and types of batteries.

In the preferred configuration, each shelf 140 is 19.055″×8.858″, and(depending on battery type) can support up to 8 batteries. With twoshelves per carrier, and four carriers in the frame, the preferredembodiment supports up to 64 batteries being tested at the same time. Tomaximize testing efficiency, the shelving is also designed to maximizeairflow in the chamber through four hundred and sixty 370 mm holes. Thispreferred hole sizing and alignment allows for sufficient airflow duringtesting while maintaining structural integrity, but can optionally bevaried as long as sufficient airflow and structural integrity aremaintained.

The preferred shelf is non conductive and light weight, made of FR4glass epoxy, a substance commonly used in the manufacturing of circuitboards. In most testing application, this shelf will be used. Alternateshelves may be used interchangeably. In one alternative the shelf ismade of aluminum and anodized to provide a non conductive surface. It isthen milled and tested to very tight flatness tolerances. This shelf maybe preferred for battery testing where the height of the battery isbeing monitored during temperature and charging cycles, dictating theneed for a very flat surface. Batteries that are on the shelf may expandunder certain electrical and/or temperature conditions. A tester maymeasure the vertical expansion (height) of the battery to insure itremains within the specifications it is designed for. The flatness ofthe alternate shelf is very important for this use case, as to notintroduce fluctuations in the surface height that may affect the outcomeof the test. In such a case, for example, the shelf needing a very tightflatness tolerance may be milled to have an overall flatness with amaximum deviation of 1 millimeter, and local flatness with a maximumdeviation of 0.25 millimeter across any 100 square millimeter regionwithin the surface. The specific flatness tolerance may vary based onthe specific battery type and test requirement.

Flexible Cable Carrier, with Support and Mounting

Referring also to FIGS. 7-9, connecting to the carrier 130 beneath eachshelf 140, flexible cable carriers 320 guide wiring and allows eachcarrier to slide out on rails without requiring disconnection of anybatteries or other wiring. Flexible cable carriers are preferablychained tracks, such as IGUS tracks, which support wiring or othercabling within. Flexible cable carrier tracks 320 may be guided on guiderails 500 connected to the underside of carrier 130 on each side of eachshelf 140. As carrier 130 is slid in or out of frame 300, the flexportion of the cable carrier track adjusts and maintains the cablelocation, allowing wiring to remain connected. Wiring 900 guided andprotected within the cable carrier track connects at one end to theABIB, and the other end is guided out of the frame to exit through port910 in the chamber and connects to the external system powering andmonitoring the batteries.

While under test, each battery is charged and discharged. During thesecycles the battery voltage is also read. This is accomplished with 4physical connections made to each battery under test. There are Force+and Force− connections as well as Sense+ and Sense−. The Force+/−linesprovide the charge from the external device to the battery. Typicalconnections support up to 20 AMPs of current, but for differentbatteries and test requirements other connections supporting up to 100AMPs or greater may be used. The Sense+/−line provide a KelvinConnection circuit to read the voltage of the battery. This method ofsensing is required so that there is no introduction of current into theequation, which would then introduce the resistance and voltage drops ofthe cabling system. Both of these pairs of wires must be routed to eachbattery. To support a battery testing maximum count per shelf of 8batteries (16 per carrier) a cable harness of 16 pairs of cables pershelf is routed through the flexible cable carrier track. Positionedunder each carrier and connected to the ABIB, the flexible cable carriertrack routing allows each carrier to be pulled out on rails for easyaccess to the batteries under test.

Battery Interface Board (ABIB)

Referring also to FIGS. 10, 11A, & 11B, ABIBs 150 connect into thecenter section of carrier 130. The ABIBs provide the ability toconfigure the ATP for testing different battery types simply by changingthe AES battery interface board. The ABIBs provide the connectivitybetween the Battery and an external testing system. Different ABIBs arerequired for testing different battery types, adjusting for sensing,density, and connection requirements of various batteries.

To fit into the carrier, each ABIB is preferably sized at19.188″×1.125″. Each ABIB is a circuit board providing signaling andphysical connection from/to the battery and the cable harness connectingto the external testing device. The interface cabling to the ABIBincludes connectors, which allows easily the decoupling of the ABIB fromthe cabling harness. This makes the ABIBs easily swappable, allowingchanging for different battery types without having to recable all theway through the system to the external device. The battery interfaceboards are interchangeable depending on battery type and much like theinterchangeable shelving provide flexibility in the testing environmentas well as future use. Holes in each ABIB may align with pins in thecarrier to rapidly connect, orient, and position each ABIB between theadjacent shelves, although alternate connection mechanisms between ABIBand carrier may be used.

ABIBs are available for cell batteries (ATP-C 1010), coin cell batteries(ATP-CC 1020), pack batteries (ATP-P 1030), and cylindrical cellbatteries (ATP-BIB-P12 1040, which is configurable with different cellholders for AAA, AA, C, D, 18650, and 21700 batteries, which connectinto the ABIB). Referring also to FIG. 12, ATP-C boards 1010 may utilizepaired spring-loaded terminal clips 1200 to clamp to battery leads, andmay be configured for testing different number of batteries (12 or 16preferred). ATP-CC boards 1020 may directly connect to coin cellbatteries. Referring also to FIG. 13, ATP-P boards 1030 may use aconnector and flex cable 1300 to connect each battery 1310 to the ABIB.Referring also to FIG. 14, as pack batteries come in a variety of sizes,with different specific connectors and connector locations depending onthe battery, flex cable 1300 may be sized and connector configured forthe specific battery geometry and connection used.

OTHER EMBODIMENTS

If additional battery testing surface conditions are required by batterytesters, a new shelf may be used and integrated into thecarrier—allowing continued use and reuse of the testing environment asnew testing requirements are defined.

For testing different battery types, new ABIBs may be implementedmatching the connection requirements of the specific battery type andfitting the form factor for connection into the carrier.

As an alternative to use within an environmental test chamber, the ATPmay be stood on its own, installed within a rack, or setup in a stackedarrangement of multiple ATPs, with each ATP connected to the externalsystem which power cycles and monitors the batteries. Such configurationenables rapid testing of many batteries with ease through swappingbatteries by sliding out shelves of the ATP and connecting/disconnectingbatteries to the ABIBs. This may be preferred in scenarios that do notrequire testing under specific environmental conditions, such asverifying power status of an entire production run while placing asmaller selection through more stringent environmental condition tests.

It is to be understood that the above description is intended to beillustrative, and not restrictive. Many other embodiments will beapparent to those of skill in the art upon reviewing the abovedescription. The scope of the invention should, therefore, be determinedwith reference to the appended claims, along with the full scope ofequivalents to which such claims are entitled.

What is claimed is:
 1. A battery test platform system for insertion intoan environmental test chamber and connection to an external systempowering and monitoring batteries during test, the system comprising: aframe having two side walls, a bottom wall, and a side wall gap in oneof the side walls allowing environmental conditions from theenvironmental test chamber to flow properly through the battery testplatform system; eight frame rails attached to the side walls; fourcarriers, each carrier connecting to two frame rails to slide in and outof the frame; two non-conductive shelves inserted into each carrier,wherein each non-conductive shelf: is made of FR4 glass epoxy; containsfour hundred and sixty holes, each hole having a diameter of threehundred and seventy millimeters; and has a very tight flatnesstolerance; sixteen flexible cable carriers, positioned with one flexiblecable carrier under each shelf, wherein each flexible cable carrier is achained track such that a flex region of the chained track changes asthe carrier is slid in or out of the frame, maintaining wiring positionsof any wiring guided through the track; four battery interface boards(ABIBs) inserted one per carrier between the two non-conductive shelvesin each carrier; and wiring guided through each of the flexible cablecarriers such that each flexible cable carrier guides a wiring bundleconnected from one end of the ABIB on the carrier above the flexiblecable carrier to exiting the battery test platform system, wherein thewiring bundle includes wiring for a Force+, a Force−, a Sense+, and aSense− connection per battery being tested on the shelf above theflexible cable carrier; wherein each ABIB is swappable to change thetype of battery being tested, and has connections to test up to sixteenbatteries (eight per shelf), and includes one of the following:spring-loaded terminal clips for connection to cell batteries; coin cellconnectors for connection to coin cell batteries; cylindrical cellbattery holders with connectors for connection to AAA, AA, C, D, 18650,or 21700 batteries; and connectors for flex cable connectors to connectto pack batteries.